Back cushion module for a vehicle seating assembly

ABSTRACT

A vehicle seating assembly includes a seating frame defined by a seatback frame and a seat frame. A plurality of distinct assembly modules are configured for attachment with the seating frame. The plurality of distinct assembly modules include a back cushion module, a hard back module, a seat cushion module, and a headrest module. The back cushion module and hard back module are operably coupled together. The headrest module extends over and operably couples the back cushion module with the seat cushion module to substantially encompass the seating frame. The seat cushion module is positioned on the seat frame in front of the seatback frame. First and second side trim pieces are configured to extend over the seat frame concealing side portions of the seat cushion module.

FIELD OF THE DISCLOSURE

The present invention generally relates to a back cushion, and moreparticularly to a back cushion module for a vehicle seating assembly.

BACKGROUND OF THE DISCLOSURE

Vehicle seating assemblies typically include a seatback to support aback of a passenger in an upright sitting position and various reclinedpositions. Similar to other portions of a vehicle seating assembly,seatbacks are commonly designed to support a passenger in the uprightsitting position upon acceleration, change in direction, and collisionof the vehicle. Accordingly, seatbacks are substantially rigid andsizeable in construction.

SUMMARY OF THE DISCLOSURE

According to another aspect of the present disclosure, a vehicle seatingassembly includes a seating frame defined by a seatback frame and a seatframe. A plurality of distinct assembly modules are configured forattachment with the seating frame. The plurality of distinct assemblymodules include a back cushion module, a hard back module, a seatcushion module, and a headrest module. The back cushion module and hardback module are operably coupled together. The headrest module extendsover and operably couples the back cushion module with the seat cushionmodule to substantially encompass the seating frame. The seat cushionmodule is positioned on the seat frame in front of the seatback frame.First and second side trim pieces are configured to extend over the seatframe concealing side portions of the seat cushion module.

According to yet another aspect of the present disclosure, a vehicleseating assembly includes a seatback frame encompassed by a plurality ofdistinct assembly modules including a back cushion module, a hard backmodule, a seat cushion module, and a headrest module. The back cushionmodule and hard back module are operably coupled together. The headrestmodule extends over and operably couples the back cushion module withthe seat cushion module to substantially encompass the seating frame.

According to one aspect of the present disclosure, a method of making avehicle seating assembly includes constructing a seating assembly framehaving a seatback frame. A plurality of distinct assembly modules areprovided that include a back cushion module, a hard back module, and aheadrest module. The back cushion module and hard back module arecoupled to conceal the seatback frame. A base of the headrest module iscoupled with a top of the back cushion module and the seat cushionmodule.

According to still another aspect of the present disclosure, a vehicleseating assembly includes a plurality of distinct assembly modules thatare constructed at a remote site and brought to an assembly plant forfinal construction. The distinct assembly modules include a back cushionmodule, a hard back module, a seat cushion module, and a headrestmodule. Each of the modules includes quick-attach fastener arrangements,such that minimal tools are required to assembly the seatback. Inaddition, as a result of preassembly of each of the modules, the vehicleseating assembly can be constructed in minimal time and at minimal cost.

These and other aspects, objects, and features of the present disclosurewill be understood and appreciated by those skilled in the art uponstudying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a front perspective view of one embodiment of a vehicleseating assembly of the present disclosure;

FIG. 2 is a front perspective partially exploded view of the vehicleseating assembly of FIG. 1;

FIG. 3 is a front perspective view of one embodiment of a seatback ofthe present disclosure;

FIG. 3A is a front perspective partially exploded view of the seatbackof FIG. 3, illustrating a back cushion module, a hard back module, and aheadrest module separated from the underlying frame;

FIG. 4 is a front perspective view of a headrest module of the presentdisclosure;

FIG. 4A is a front perspective exploded view of the headrest module ofFIG. 4;

FIG. 5 is a front perspective view of the back cushion module;

FIG. 6 is a front perspective view of a coverstock removed from acushion portion of the back cushion module;

FIG. 7 is a front perspective partially exploded view of the backcushion module of FIG. 5;

FIG. 8 is a front perspective view of a composite back carrier of theback cushion module;

FIG. 9 is a front elevational view of the composite back carrier of FIG.8;

FIG. 10 is a rear perspective view of the composite back carrier of FIG.8;

FIG. 11 is a rear elevational view of the composite back carrier of FIG.8;

FIG. 12 is a top perspective view of a seat cushion module of thepresent disclosure;

FIG. 13 is a top perspective partially exploded view of the seat cushionmodule of FIG. 12;

FIG. 14 is a top perspective view of the seat cushion module with theunderlying support frame removed;

FIG. 15 is a top perspective partially exploded view of the seat cushionmodule of FIG. 14; and

FIG. 16 is another top perspective partially exploded view of the seatcushion module of FIG. 14.

DETAILED DESCRIPTION OF THE EMBODIMENTS

For purposes of description herein, the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the disclosure as oriented in FIG. 1. However,it is to be understood that the disclosure may assume variousalternative orientations, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of theinventive concepts defined in the appended claims. Hence, specificdimensions and other physical characteristics relating to theembodiments disclosed herein are not to be considered as limiting,unless the claims expressly state otherwise.

In this document, relational terms, such as first and second, top andbottom, and the like, are used solely to distinguish one entity oraction from another entity or action, without necessarily requiring orimplying any actual such relationship or order between such entities oractions. The terms “comprises,” “comprising,” or any other variationthereof, are intended to cover a non-exclusive inclusion, such that aprocess, method, article, or apparatus that comprises a list of elementsdoes not include only those elements but may include other elements notexpressly listed or inherent to such process, method, article, orapparatus. An element proceeded by “comprises . . . a” does not, withoutmore constraints, preclude the existence of additional identicalelements in the process, method, article, or apparatus that comprisesthe element.

Referring to the embodiment generally illustrated in FIGS. 1-16,reference numeral 10 generally designates a vehicle seating assemblythat includes a seating frame 12 defining a seatback frame 14 and a seatframe 16. A plurality of distinct assembly modules 18 are configured forattachment with the seating frame 12. The plurality of distinct assemblymodules 18 include a back cushion module 20, a hard back module 22, aseat cushion module 24, and a headrest module 26. The back cushionmodule 20 and the hard back module 22 are operably coupled together. Theheadrest module 26 extends over and operably couples the back cushionmodule 20 with the seat cushion module 24 to substantially encompass theseating frame 12. The seat cushion module 24 is positioned on the seatframe 16 in front of the seatback frame 14. Side trim pieces 30 areconfigured to extend over the seat frame 16 concealing side portions 34of the seat cushion module 24.

With reference to FIGS. 1 and 2, the vehicle seating assembly 10 isconfigured for installation in a vehicle, such as a car, a truck, or avan. A seat base 38 of the vehicle seating assembly 10 is supported on arail slide assembly 40 that allows for fore and aft movement of thevehicle seating assembly 10 relative to the vehicle. Rails 42 aresecured with a floor of the vehicle, while slides 44 are operablycoupled with the vehicle seating assembly 10. The slides 44 are insliding engagement with the rails 42. The slides 44 can be adjusted andlocked by a user using a forward slide control 46. In addition, amultitude of side controls, including a lumbar support control 48, athigh support control 50, and a seatback pivot control 52 that allowsfor pivoting movement of a seatback 53 are provided proximate the seatcushion module 24, and allow for adjustment of the seatback 53 and theseat base 38 to accommodate passengers. A receiver 54 for a seatbeltassembly is disposed on the vehicle seating assembly 10 to secure apassenger during a collision event. In addition, a forward trimcomponent 56 and the side trim pieces 30 are disposed about the seatbase 38. The trim components 56 cover the seat frame 16 and structuralcomponents of the seat base 38 and the seat cushion module 24. Asillustrated in FIG. 2, the seatback 53 is pivotal relative to the seatbase 38 about a pivot rod (or torsion bar) 58 proximate a rear portion60 of the seat base 38.

Turning now to FIGS. 3 and 3A, the seatback 53 is operably coupled withthe seat base 38 and includes seatback side bolsters 70 that cradle apassenger resting against the seatback 53. The bolsters 70 are formed inthe back cushion module 20 and may be partially supported by the hardback module 22. The hard back module 22, as illustrated in FIG. 3,includes a hard back panel 71 having a lower lip 72 that extends belowthe remainder of the seatback 53 as well as the seat cushion module 24and which partially wraps around a rear portion of the seat cushionmodule 24. In addition, the hard back module 22 includes scallopedsections 69 on a lower portion thereof The scalloped sections 69 areconfigured to accommodate the recliner mechanism associated with therelative inclination of the seatback 53. The hard back module 22 alsoincludes a plurality of fastener mechanisms 75 disposed about aperiphery of the hard back module 22. The fastener mechanisms 75 allowfor direct connection of the hard back panel 71 to the back cushionmodule 20. Consequently, the hard back panel 71 abuts, but does notcouple directly with, the seatback frame 14. Also, the hard back module22 has a centrally-located wall 77 configured as a pocket to provideadditional storage to passengers. The wall 77 may be constructed of thesame material or different material than the hard back panel 71. A gap79 is formed at a top portion of the hard back panel 71, and isconfigured to accommodate the headrest module 26.

As illustrated in FIG. 3A, the back cushion module 20, the headrestmodule 26, and the hard back module 22, encompass the seatback frame 14and a side airbag 74, such that the seatback frame 14 is not visibleafter installation of the back cushion module 20, the headrest module26, and the hard back module 22. The seatback frame 14 includes aninboard side support 73, an outboard side support 76, and top and bottomcross members 78, 80, respectively. Notably, the headrest module 26includes a headrest 81 with engagement posts 64 configured to beinserted through a headrest tray 83 and into the top cross member 78 ofthe seatback frame 14. The headrest tray 83 includes a downwardly tippedfront lip 85 and a rear upwardly extending back wall 87. The headresttray 83 also includes two downwardly extending supports 89 that engagethe seatback frame 14 and back cushion module 20. Additionally, the sideairbag 74 is disposed on the outboard side support 76 of the seatbackframe 14 and configured to deploy between the back cushion module 20 andthe hard back module 22.

Referring now to the illustrated headrest module 26 of FIGS. 4 and 4A,the headrest module 26 includes a frame 90 operably coupled with theengagement posts 64. The frame 90 supports a forward structural member91 and a rearward structural member 92. The forward structural member 91and the rearward structural member 92 are connected via mechanicalfasteners 93 that extend through the frame 90 of the headrest module 26.The forward structural member 91 supports a headrest cushion 94. Acoverstock 95 and a spacer fabric 96 are disposed over the headrestcushion 94 and are in secure engagement with the forward structuralmember 91 of the headrest module 26. A rear side of the rearwardstructural member 92 includes a headrest back panel 97 that conceals thestructural components of the headrest module 26 from view frompassengers sitting behind the vehicle seating assembly 10. The frame 90of the headrest module 26 includes a latching mechanism 98 toaccommodate rotational movement of the frame 90 relative to theengagement posts 64. Accordingly, the relative angle of the frame 90,and consequently the headrest cushion 94, can be adjusted to a desiredposition to accommodate passengers of different heights and sizes.

With reference to FIGS. 5-7, the back cushion module 20 includes aseatback coverstock 100 that extends over a back cushion 102 of the backcushion module 20. In addition, different varieties of the seatbackcoverstock 100 may be used to cover the back cushion 102 of the backcushion module 20. In the illustrated embodiment, a first coverstockmaterial 104 is used to cover the bolsters 70 and a lower back 106 ofthe back cushion module 20. A second coverstock material 107 covers acentral and upper back 108. Mechanical fasteners, glue, or other formsof attachment may be used to secure the seatback coverstock 100 with theback cushion module 20.

With reference now to the embodiment generally illustrated in FIG. 6,the back cushion 102 of the back cushion module 20 includes integrallyformed trenches 110 configured to receive fasteners disposed on a backsurface 112 of the seatback coverstock 100. In addition, an upperportion of both the seatback coverstock 100 and the back cushion 102includes a recess 114 configured to accommodate the headrest tray 83 andthe headrest module 26. Further, a lumbar adjustment assembly 120 (FIG.7) in the back cushion module 20 is also installed and configured to beadjusted by the lumbar support control 48 disposed on the seat base 38(FIGS. 1 and 2).

With reference to FIG. 7, the back cushion module 20 includes a backcarrier 122 configured to support the lumbar adjustment assembly 120 andalso to receive the back cushion 102 and the seatback coverstock 100. Itis generally contemplated that the back carrier 122 is constructed froma polymeric material. However, the back carrier 122 could also beconstructed from a variety of other materials, including metals orcomposites.

With reference to FIGS. 8-11, the back carrier 122 is illustrated inmore detail. The back carrier 122 includes a plurality of frameattachment features 124 in the form of side tabs 126 and a lower crossmember support 127. The side tabs 126 actively engage the inboard sidesupport 73 and the outboard side support 76 of the seatback frame 14securing the same to the seatback frame 14. The back carrier 122includes two upper apertures 128 configured to receive engagement posts64 of the headrest 81. In addition, the back carrier 122 includes aninner flange 144 that provides additional rigidity to the back carrier122. Fastener apertures 132 are disposed about a periphery of the backcarrier 122 and are configured to receive fasteners on one or both ofthe seatback frame 14 and the back cushion 102. The back carrier 122generally includes side members 134 that are coupled by a top member 136and a bottom member 138. The bottom member 138 includes an arcuatesupport in the form of the lower cross member support 127 that opensrearward, and which wraps about the torsion bar 58 (FIG. 2) of thevehicle seating assembly 10. A support flange 145 extends upward fromthe arcuate support and includes flange reinforcements 146 extendingacross the support flange 145.

With reference to FIGS. 10 and 11, the frame attachment features 124 aredesigned to fit into the inboard side support 73 and the outboard sidesupport 76 to maintain the back carrier 122 in position on the seatbackframe 14. At the same time, the top member 136 of the back carrier 122is aligned with adjacent to the top cross member 78 of the seatbackframe 14. Accordingly, the back carrier 122 closely receives theseatback frame 14 such that minimal space is disposed between the backcarrier 122 and the seatback frame 14.

With reference now to FIGS. 12 and 13, the illustrated seat base 38includes the slides 44 of the seat cushion module 24 supported on therails 42. Seat side supports 170 support the seat cushion module 24above the rails 42 and the slides 44. As shown in FIG. 13, the seatcushion module 24 is supported on the seat side supports 170 byconnecting brackets 172. In addition, the seatbelt fastener receiver 54is also disposed adjacent to the seat cushion module 24 and operablycoupled with the vehicle.

With reference to FIGS. 13-16, the seat cushion module 24 includes aseat coverstock 176 that extends over a seat cushion 178. Similar to theback cushion module 20, the seat coverstock 176 may include differentvarieties over different portions of the seat cushion 178. The seatcoverstock 176 and the seat cushion 178 are operably coupled with acomposite cushion pan 180. The composite cushion pan 180 includes arearward support 182 defining an intermediate open area 184 and aforward support 186 pivotally coupled to the rearward support 182 atpivot joints 183. The forward support 186 is pivotally coupled to therearward support 182 to provide adjustability and increased or decreasedsupport to the thighs of a passenger. Side thigh supports 185 alsoprovide thigh support to passengers. The forward support 186 includesarranging upwardly extending flanges 191 in a honeycomb structure 192across a lower wall 193 of the forward support 186.

With reference again to FIGS. 13-16, the forward support 186 includeshooked tabs 187 that extend below the forward support 186 and forward.The hooked tabs 187 engage an adjustable cross bar 189 that can beraised or lowered to accommodate the legs of different sized passengers.The forward support 186 may be adjusted manually or by a motorizedassembly. The forward support 186 is pivotally adjustable up and downrelative to the rearward support 182. The forward support 186 includes aplurality of apertures 188 configured to receive mechanical fastenersthat wrap the seat coverstock 176 about a forward portion of the seatcushion module 24. In addition, a suspension assembly 190 is disposed inthe intermediate open area 184 of the rearward support 182. Thesuspension assembly 190 supports the seat cushion 178 and the seatcoverstock 176, and is configured to withstand both the static anddynamic loads associated with a seated passenger during travel.

Referring again to FIGS. 13-16, the vehicle seating assembly 10disclosed herein is constructed from the various modules set forth indetail above. It will be understood that the back cushion module 20, thehard back module 22, the seat cushion module 24, and the headrest module26 are all integrally formed as separate and distinct modules at remotesites. Subsequently, after construction, each of the modules is sent toa manufacturing facility where the modules are installed over theseating frame 12. This construction allows for quick and easymanufacturing and independence of each of the modules. That is, thatmodules can be swapped in and out of the vehicle seating assembly 10without having to deconstruct the entire vehicle seating assembly 10.This provides minimized production time, increased savings ofproduction, and an overall better product. Further, additions or changescan be made to separate modules without impacting other modules on thevehicle seating assembly 10.

Vehicle seating assemblies are traditionally assembled piece by piecefrom the floor up. Complexities of the seating assemblies can beachieved using this technique, but the process is time consuming andcostly. In addition, lack of modularity results in costly and timeintensive repairs and replacement. A modular system, such as that setforth above provides an ideal way to construct multiple modules atdifferent locations or facilities at different geographic locations, andbring them to a single site for to complete the final vehicle seatingassembly. In addition, this system provides an easy method for buildinga seating assembly. Specifically, only a few parts (each of the modules)are brought together and secured with the seating frame. Accordingly,few fasteners and tools to tighten those fasteners are needed. Moreover,repair or replacement of parts is simplified. If, for example, the seatcushion assembly has a defect or has been damaged, the seat cushionassembly can be removed from the vehicle seating assembly and replacedin just a few minutes.

It will be understood by one having ordinary skill in the art thatconstruction of the described disclosure and other components is notlimited to any specific material. Other exemplary embodiments of thedisclosure disclosed herein may be formed from a wide variety ofmaterials, unless described otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or moveable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the disclosure as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present disclosure. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present disclosure, and further it is to beunderstood that such concepts are intended to be covered by thefollowing claims unless these claims by their language expressly stateotherwise.

What is claimed is:
 1. A vehicle seating assembly comprising: a seatingframe defined by a seatback frame and a seat frame; a plurality ofdistinct assembly modules configured for attachment with the seatingframe, the plurality of distinct assembly modules including: a backcushion module; a hard back module; a seat cushion module; and aheadrest module; wherein the back cushion module and hard back moduleare operably coupled together, and wherein the headrest module extendsover and operably couples the back cushion module with the seat cushionmodule to substantially encompass the seating frame, and further whereinthe seat cushion module is positioned on the seat frame in front of theseatback frame; and first and second side trim pieces configured toextend over the seat frame concealing side portions of the seat cushionmodule.
 2. The vehicle seating assembly of claim 1, wherein the hardback module is mechanically fastened to the back cushion module.
 3. Thevehicle seating assembly of claim 1, further comprising: a headrest traythat operably couples the back cushion module, seatback frame, and hardback module.
 4. The vehicle seating assembly of claim 3, wherein theheadrest tray further includes an upwardly-extending back wall and adownwardly extending front lip.
 5. The vehicle seating assembly of claim1, further comprising: a polymeric back carrier that provides structuralrigidity to the back cushion module and which abuts the seatback frameand is operably coupled directly with the hard back module.
 6. Thevehicle seating assembly of claim 5, wherein the back carrier includestwo upper apertures aligned with apertures in the seatback frame andwhich are configured to receive engagement posts of the headrest module.7. The vehicle seating assembly of claim 1, wherein the back carrierincludes a lower member having an arcuate support that opens rearwardly.8. A vehicle seating assembly comprising: a seatback frame encompassedby a plurality of distinct assembly modules including: a back cushionmodule; a hard back module; a seat cushion module; and a headrestmodule; the back cushion module and hard back module being operablycoupled together, wherein the headrest module extends over and operablycouples the back cushion module with the seat cushion module tosubstantially encompass the seatback frame.
 9. The vehicle seatingassembly of claim 8, wherein the hard back module includes a lower lipthat extends below the back cushion module and which partially wrapsaround a portion of the seat cushion module.
 10. The vehicle seatingassembly of claim 8, wherein the hard back module is mechanicallyfastened to the back cushion module.
 11. The vehicle seating assembly ofclaim 8, further comprising: a headrest tray that operably couples theback cushion module, seatback frame, and hard back module.
 12. Thevehicle seating assembly of claim 11, wherein the headrest tray furtherincludes an upwardly-extending back wall and a downwardly extendingfront lip.
 13. The vehicle seating assembly of claim 8, furthercomprising: a polymeric back carrier that provides structural rigidityto the back cushion module and which abuts the seatback frame and isoperably coupled directly with the hard back module.
 14. The vehicleseating assembly of claim 13, wherein the back carrier includes twoupper apertures aligned with apertures in the seatback frame and whichare configured to receive engagement posts of the headrest module.
 15. Amethod of making a vehicle seating assembly comprising: constructing aseating assembly frame having a seatback frame; providing a plurality ofdistinct assembly modules including: a back cushion module; a hard backmodule; and a headrest module; coupling the back cushion module and hardback module to conceal the seatback frame; and coupling a tray of theheadrest module with a top of the back cushion module and the hard backmodule.
 16. The method of claim 15, further comprising: positioning aheadrest tray over the back cushion module, seatback frame, and hardback module which operably couples the back cushion module, seatbackframe, and hard back module.
 17. The method of claim 16, furthercomprising: forming the headrest tray to include an upwardly-extendingback wall and a downwardly extending front lip.
 18. The method of claim17, wherein the hard back module is mechanically fastened to the backcushion module.
 19. The method of claim 15, further comprising: couplinga polymeric back carrier with the back cushion module; and coupling theback carrier directly with the hard back module.
 20. The method of claim15, further comprising: forming two upper apertures in the back carrierwhich are aligned with apertures in the seatback frame and which areconfigured to receive engagement posts of the headrest module.